A friction material for a clutch pad comprising: a plurality of fibers; and, a filler material including at least 0.1% and at most 100% calcium silicate particles by weight based on total weight of the filler. A friction material for a clutch comprising: a plurality of fibers; a filler material including at least 0.1% and at most 40% calcium silicate particles by weight based on total weight of the friction material; the calcium silicate particles characterized by a specific surface area of at least 40 m.sup.2/g and an average particle size of at most 60 ?m; and, a binder. In an example aspect, the calcium silicate particles are characterized by a spherical morphology. In another example aspect, the calcium silicate particles are characterized by a specific surface area of about 105 m.sup.2/g and an average particles size of about 10 ?m.

A clutch plate assembly includes a central axis, a clutch plate with a first friction surface and a radially outer depressed portion, and a friction material ring. The friction material ring is bonded to the first friction surface and extends radially outside of the first friction surface such that an outer portion of the friction material ring is axially aligned with the clutch plate radially outer depressed portion. In an example embodiment, the first friction surface is disposed at an acute angle to a plane orthogonal to the central axis. In some example embodiments, the first friction surface is conical. In an example embodiment, the radially outer depressed portion is conical and axially offset from the first friction surface. In an example embodiment, the radially outer depressed portion is manufactured by machining, stamping, or coining.

A friction material for a motor vehicle drive train component is provided. The friction material includes an outer circumference, an inner circumference, an engagement surface configured for engaging with and disengaging from a mating component and a coined section extending between at least one of the outer circumference and the engagement surface and the inner circumference and the engagement surface. A method of forming a friction material for a motor vehicle drive train component is also provided. The method includes attaching a first axial surface of the friction material to a support and coining at least one of an inner circumference and an outer circumference at a second axial surface of a friction material to form a coined section. The second axial surface is on an opposite side as the first axial surface.

A method of fabricating a torque converter, including: forming a turbine shell including a first annular portion with a first surface having a first roughness and forming a radially outermost portion of the turbine shell; fixing a first plurality of blades to the turbine shell; forming an impeller shell including a second annular portion with a second surface having a second roughness; fixing a second plurality of blades to the impeller shell; removing at least a portion the first or second surface without the use of particulate matter or a liquid; increasing the first or second roughness of the first or second surface from which the at least a portion is removed; applying an adhesive to the first or second surface from which the at least a portion is removed; and bonding, with the adhesive, friction material to the first or second surface.

A friction material for a clutch pad comprising: a plurality of fibers; and, a filler material including at least 0.1% and at most 100% calcium silicate particles by weight based on total weight of the filler. A friction material for a clutch comprising: a plurality of fibers; a filler material including at least 0.1% and at most 40% calcium silicate particles by weight based on total weight of the friction material; the calcium silicate particles characterized by a specific surface area of at least 40 m.sup.2/g and an average particle size of at most 60 ?m; and, a binder. In an example aspect, the calcium silicate particles are characterized by a spherical morphology. In another example aspect, the calcium silicate particles are characterized by a specific surface area of about 105 m.sup.2/g and an average particles size of about 10 ?m.

A friction material for a clutch comprising: a plurality of fibers; a filler material: and, a binder including at least 3% and at most 50% silane by weight based on total weight of the binder. The friction material is devoid of added water. In an example aspect, the silane is an organosilane having a reactive organic ureido group and a hydrolyzable inorganic triethoxysilyl group. In an example aspect, the binder further includes phenolic resin, wherein the phenolic resin forms byproduct water upon curing to react with the hydrolyzable inorganic triethoxysilyl group to form a cross-linked binder. A method forming a hybrid matrix composite for a flexible clutch friction material is also disclosed.

The present invention is a clutch plate attached to the inner surface of the impeller and/or turbine of a torque converter. The clutch plate supports friction material that enables the engagement of the turbine and impeller in the form of a turbine clutch. The clutch plate acts to relieve strain on the impeller shell when engagement occurs. In addition, the clutch plate provides an enlarged vertical surface to hold additional friction material.

A method of fabricating a torque converter, including: forming a turbine shell including a first annular portion with a first surface having a first roughness and forming a radially outermost portion of the turbine shell; fixing a first plurality of blades to the turbine shell; forming an impeller shell including a second annular portion with a second surface having a second roughness; fixing a second plurality of blades to the impeller shell; removing at least a portion the first or second surface without the use of particulate matter or a liquid; increasing the first or second roughness of the first or second surface from which the at least a portion is removed; applying an adhesive to the first or second surface from which the at least a portion is removed; and bonding, with the adhesive, friction material to the first or second surface.

An oil-flooded single-plate or multi-plate lockup clutch is provided in a torque transfer device. The torque transfer device may, for example, be a converter, a dual clutch, a starting clutch, a manual shifter or power shifting clutch, having a piston to engage the clutch and a damper. In accordance with the present disclosure, the piston together with a housing of the torque transfer device forms a closed pressure chamber when the clutch is engaged and at least one oil flow opening is provided in the piston in an area outside of the pressure chamber. The torque transfer device preferably has a damper and the piston of the clutch forms a part of the damper and may be designed as a retainer for springs of the damper.

The present invention provides a lock-up clutch for a torque converter. The lock-up clutch includes an outer carrier, an inner carrier, a first friction plate, a rotation of which is restricted by the outer carrier, and a second friction plate, a rotation of which is restricted by the inner carrier. All key grooves of the outer and inner carriers are opened in two radial opposite directions, and flow path grooves defined between friction members attached to the friction plate are aligned with circumferential positions of keys of the friction plate. Therefore, oil for cooling a clutch pack may smoothly flow through the inner carrier, the flow path grooves, and the outer carrier.